Intercalates and exfoliates formed with monomeric carbonyl-functional organic compounds, including carboxylic and polycarboxylic acids; aldehydes; and ketones; composite materials containing same and methods of modifying rheology therewith

ABSTRACT

Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer carbonyl-functional compound and/or a carboxylic acid-functional compound to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 Å (as measured after water removal to a maximum of 5% by weight water), up to about 100 Å and preferably in the range of about 10-45 Å, so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix. Alternatively, the intercalated complex can be exfoliated prior to combination with the organic liquid or the matrix polymer.

FIELD OF THE INVENTION

The present invention is directed to intercalated layered materials, and exfoliates thereof, manufactured by sorption (adsorption and/or absorption) of one or more functional monomeric organic compounds between planar layers of a swellable layered material, such as a phyllosilicate or other layered material, to expand the interlayer spacing of adjacent layers to at least about 5 Angstroms (Å), preferably at least about 10 Å. More particularly, the present invention is directed to intercalates preferably having at least two layers of monomeric organic compounds sorbed on the internal surfaces of adjacent layers of the planar platelets of a layered material, such as a phyllosilicate, preferably a smectite clay, to expand the interlayer spacing to at least about 5 Å, preferably at least about 10 Å, more preferably to at least about 20 Å, and most preferably to at least about 30-45 Å, up to about 100 Å, or disappearance of periodicity. The intercalated layered materials preferably have at least two layers of carbonyl-functional or carboxylic acid-functional molecules sorbed on the internal surfaces between adjacent layers of the planar platelets of the layered material, such as a phyllosilicate, preferably a smectite clay. The resulting intercalates are neither entirely organophilic nor entirely hydrophilic, but a combination of the two, and easily can be exfoliated and combined as individual platelets with a polar organic solvent carrier to form a viscous composition having a myriad of uses. The resulting polar organic solvent carrier/intercalate or carrier/platelet composite materials are useful as plasticizers; for providing increased viscosity and elasticity to thermoplastic and thermosetting polymers; e.g., for plasticizing polyvinyl chloride; for food wrap having improved gas impermeability; electrical components; food grade drink containers; particularly for raising the viscosity of polar organic liquids; and for altering one or more physical properties of a matrix polymer, such as elasticity and temperature characteristics, e.g., glass transition temperature and high temperature resistance.

BACKGROUND OF THE INVENTION AND PRIOR ART

It is well known that phyllosilicates, such as smectite clays, e.g., sodium montmorillonite and calcium montmorillonite, can be treated with organic molecules, such as organic ammonium ions, to intercalate the organic molecules between adjacent, planar silicate layers, for bonding the organic molecules with a polymer, for intercalation of the polymer between the layers, thereby substantially increasing the interlayer (interlaminar) spacing between the adjacent silicate layers. The thus-treated, intercalated phyllosilicates, having interlayer spacings of at least about 10-20 Å and up to about 100 Å, then can be exfoliated, e.g., the silicate layers are separated, e.g., mechanically, by high shear mixing. The individual silicate layers, when admixed with a matrix polymer, before, after or during the polymerization of the matrix polymer, e.g., a polyamide --see U.S. Pat. Nos. 4,739,007; 4,810,734; and 5,385,776--have been found to substantially improve one or more properties of the polymer, such as mechanical strength and/or high temperature characteristics.

Exemplary of such prior art composites, also called "nanocomposites", are disclosed in published PCT disclosure of Allied Signal, Inc. WO 93/04118 and U.S. Pat. No. 5,385,776, disclosing the admixture of individual platelet particles derived from intercalated layered silicate materials, with a polymer to form a polymer matrix having one or more properties of the matrix polymer improved by the addition of the exfoliated intercalate. As disclosed in WO 93/04118, the intercalate is formed (the interlayer spacing between adjacent silicate platelets is increased) by adsorption of a silane coupling agent or an onium cation, such as a quaternary ammonium compound, having a reactive group which is compatible with the matrix polymer. Such quaternary ammonium cations are well known to convert a highly hydrophilic clay, such as sodium or calcium montmorillonite, into an organophilic clay capable of sorbing organic molecules. A publication that discloses direct intercalation (without solvent) of polystyrene and poly(ethylene oxide) in organically modified silicates is Synthesis and Properties of Two-Dimensional Nanostructures by Direct Intercalation of Polymer Melts in Layered Silicates, Richard A. Vaia, et al., Chem. Mater., 5:1694-1696 (1993). Also as disclosed in Adv. Materials, 7, No. 2: (1985), pp, 154-156, New Polymer Electrolyte Nanocomposites: Melt Intercalation of Poly(Ethylene Oxide) in Mica-Type Silicates, Richard A. Vaia, et al., poly(ethylene oxide) can be intercalated directly into Na-montmorillonite and Li-montmorillonite by heating to 80° C. for 2-6 hours to achieve a d-spacing of 17.7 Å. The intercalation is accompanied by displacing water molecules, disposed between the clay platelets, with polymer molecules. Apparently, however, the intercalated material could not be exfoliated and was tested in pellet form. It was quite surprising to one of the authors of these articles that exfoliated material could be manufactured in accordance with the present invention.

Previous attempts have been made to intercalate polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA) and poly(ethylene oxide) (PEO) between montmorillonite clay platelets with little success. As described in Levy, et al., Interlayer Adsorption of Polyvinylpyrrolidone on Montmorillonite, Journal of Colloid and Interface Science, Vol. 50, No. 3, March 1975, pages 442-450, attempts were made to sorb PVP (40,000 average M.W.) between monoionic montmorillonite clay platelets (Na, K, Ca and Mg) by successive washes with absolute ethanol, and then attempting to sorb the PVP by contact with 1% PVP/ethanol/water solutions, with varying amounts of water, via replacing the ethanol solvent molecules that were sorbed in washing (to expand the platelets to about 17.7 Å). Only the sodium montmorillonite had expanded beyond a 20 Å basal spacing (e.g., 26 Å and 32 Å), at 5⁺ % H₂ O, after contact with the PVP/ethanol/H₂ O solution. It was concluded that the ethanol was needed to initially increase the basal spacing for later sorption of PVP, and that water did not directly affect the sorption of PVP between the clay platelets (Table II, page 445), except for sodium montmorillonite. The sorption was time consuming and difficult and met with little success.

Further, as described in Greenland, Adsorption of Polyvinyl Alcohols by Montmorillonite, Journal of Colloid Sciences, Vol. 18, pages 647-664 (1963), polyvinyl alcohols containing 12% residual acetyl groups could increase the basal spacing by only about 10 Å due to the sorbed polyvinyl alcohol (PVA). As the concentration of polymer in the intercalant polymer-containing solution was increased from 0.25% to 4%, the amount of polymer sorbed was substantially reduced, indicating that sorption might only be effective at polymer concentrations in the intercalant polymer-containing composition on the order of 1% by weight polymer, or less. Such a dilute process for intercalation of polymer into layered materials would be exceptionally costly in drying the intercalated layered materials for separation of intercalate from the polymer carrier, e.g., water, and, therefore, apparently no further work was accomplished toward commercialization.

In accordance with one embodiment of the present invention, intercalates are prepared by contacting a phyllosilicate with a monomeric organic compound having an electrostatic carbonyl functionality selected from the group consisting of carboxylic acids, and salts thereof; polycarboxylic acids and salts thereof; aldehydes; ketones; and mixtures thereof.

In accordance with an important feature of the present invention, best results are achieved using the monomeric organic compound, having at least one carbonyl functionality, in a concentration of at least about 2%, preferably at least about 5% by weight functional monomeric organic compound, more preferably at least about 10% by weight monomeric carbonyl-functional compound, and most preferably about 30% to about 80% by weight, based on the weight of functional monomeric organic compound and carrier (e.g., water, with or without another solvent for the functional monomeric compound) to achieve better sorption of the functional monomeric organic compound between phyllosilicate platelets. Regardless of the concentration of functional monomeric organic compound in aqueous liquid, the intercalating composition should have a monomeric carbonyl-functional compound:layered material ratio of at least 1:20, preferably at least 1:10, more preferably at least 1:5, and most preferably about 1:4 to achieve efficient intercalation of the functional monomeric organic compound between adjacent platelets of the layered material. The functional monomeric organic compound sorbed between and bonded to the silicate platelets probably via chelation-type bonding with the exchangeable cation, or like electrostatic or dipole/dipole bonding, causes separation or added spacing between adjacent silicate platelets and, for simplicity of description, all monomeric carbonyl-functional compounds are hereinafter called the "intercalant" or "intercalant monomer" or "monomer intercalant". In this manner, the monomeric carboxylic acids, monomeric polycarboxylic acids, aldehydes and/or ketones will be sorbed sufficiently to increase the interlayer spacing of the phyllosilicate in the range of about 5 Å to about 100 Å, preferably at least about 10 Å, for easier and more complete exfoliation, in a commercially viable process, regardless of the particular phyllosilicate or intercalant monomer.

In accordance with the present invention, it has been found that a phyllosilicate, such as a smectite clay, can be intercalated sufficiently for subsequent exfoliation by sorption of organic monomer compounds that have a carbonyl functionality to provide bonding of the carbonyl or carboxylic acid functional group to the internal surfaces of the layered material by a mechanism selected from the group consisting of ionic complexing; electrostatic complexing; chelation; hydrogen bonding; dipole/dipole; Van Der Waals forces; and any combination thereof. Such bonding between two functional groups of one or two intercalant monomer molecules and the metal cations bonded to the inner surfaces of the phyllosilicate platelets provides adherence between the carbonyl-functional or carbonylic acid-functional molecules and the platelet inner surfaces of the layered material. Sorption and bonding of a platelet metal cation between two oxygen atoms of the intercalant monomer molecules increases the interlayer spacing between adjacent silicate platelets or other layered material to at least about 5 Å, preferably to at least about 10 Å, and more preferably at least about 20 Å, and most preferably in the range of about 30 Å to about 45 Å. Such intercalated phyllosilicates easily can be exfoliated into individual phyllosilicate platelets before or during admixture with a liquid carrier or solvent, for example, one or more monohydric alcohols, such as methanol, ethanol, propanol, and/or butanol; polyhydric alcohols, such as glycerols and glycols, e.g., ethylene glycol, propylene glycol, butylene glycol, glycerine and mixtures thereof; aldehydes; ketones; carboxylic acids; amines; amides; and other organic solvents, for delivery of the solvent in a thixotropic composition, or for delivery of any active hydrophobic or hydrophilic organic compound, such as a topically active pharmaceutical, dissolved or dispersed in the carrier or solvent, in a thixotropic composition; or the intercalates and/or exfoliates thereof can be admixed with a polymer or other organic monomer compound(s) or composition to increase the viscosity of the organic compound or provide a polymer/intercalate and/or exfoliate composition to enhance one or more properties of a matrix polymer.

DEFINITIONS

Whenever used in this Specification, the terms set forth shall have the following meanings:

"Layered Material" shall mean an inorganic material, such as a smectite clay mineral, that is in the form of a plurality of adjacent, bound layers and has a thickness, for each layer, of about 3 Å to about 50 Å, preferably about 10 Å.

"Platelets" shall mean individual layers of the Layered Material.

"Intercalate" or "Intercalated" shall mean a Layered Material that includes a monomeric carbonyl-functional or carboxylic acid-functional monomeric compound disposed between adjacent platelets of the Layered Material to increase the interlayer spacing between the adjacent platelets to at least about 5 Å, preferably at least about 10 Å.

"Intercalation" shall mean a process for forming an Intercalate.

"Intercalant Monomer" or "Intercalant" shall mean a monomeric carbonyl-functional and/or a monomeric carboxylic acid-functional or carboxylic acid salt-functional molecule that is sorbed between Platelets of the Layered Material and complexes with the platelet surfaces to form an Intercalate.

"Intercalating Carrier" shall mean a carrier comprising water with or without an organic solvent used together with an Intercalant Monomer to form an Intercalating Composition capable of achieving Intercalation of the Layered Material.

"Intercalating Composition" shall mean a composition comprising an Intercalant Monomer, an Intercalating Carrier for the Intercalant Monomer, and a Layered Material.

"Exfoliate" or "Exfoliated" shall mean individual platelets of an Intercalated Layered Material so that adjacent platelets of the Intercalated Layered Material can be dispersed individually throughout a carrier material, such as water, a polymer, an alcohol or glycol, or any other organic solvent.

"Exfoliation" shall mean a process for forming an Exfoliate from an Intercalate.

SUMMARY OF THE INVENTION

In brief, the present invention is directed to intercalates and exfoliates thereof formed by contacting a layered phyllosilicate with a functional organic monomer (intercalant monomer), having at least one carbonyl or carboxylic acid functionality, to sorb or intercalate the intercalant monomer or mixtures of intercalant monomers between adjacent phyllosilicate platelets. Sufficient intercalant monomer is sorbed between adjacent phyllosilicate platelets to expand the spacing between adjacent platelets (interlayer spacing) to a distance of at least about 5 Å, preferably to at least about 10 Å (as measured after water removal, to a maximum water content of 5% by weight, based on the dry weight of the layered material) and more preferably in the range of about 30-45 Å, so that the intercalate easily can be exfoliated, sometimes naturally without shearing being necessary. At times, the intercalate requires shearing that easily can be accomplished, e.g., when mixing the intercalate with a polar organic solvent carrier, such as a polar organic hydrocarbon, and/or with a polymer melt to provide a platelet-containing composite material or nanocomposite--the platelets being obtained by exfoliation of the intercalated phyllosilicate.

The intercalant monomer has an affinity for the phyllosilicate so that it is sorbed between, and is maintained associated with the silicate platelets, in the interlayer spaces, and after exfoliation. In accordance with the present invention, the intercalant monomer should include a carbonyl and/or a carboxylic acid functionality to be sufficiently bound, it is hereby theorized, by a mechanism selected from the group consisting of ionic complexing; electrostatic complexing; chelation; hydrogen bonding; dipole/dipole; Van Der Waals forces; and any combination thereof. Such bonding, via the metal cations of the phyllosilicate sharing electrons with two oxygen atoms from a carbonyl or a carboxylic acid (or salt) functionality of one intercalant monomer molecule or of two adjacent intercalant monomer molecules, to an inner surface of the phyllosilicate platelets provides adherence between the carbonyl and/or carboxylic acid molecules and the platelet inner surfaces of the layered material. Such intercalant monomers have sufficient affinity for the phyllosilicate platelets to maintain sufficient interlayer spacing for exfoliation, without the need for coupling agents or spacing agents, such as the onium ion or silane coupling agents disclosed in the above-mentioned prior art. A schematic representation of the charge distribution on the surfaces of a sodium montmorillonite clay is shown in FIGS. 1-3. As shown in FIGS. 2 and 3, the location of surface Na⁺ cations with respect to the location of O, Mg, Si and Al atoms (FIGS. 1 and 2) results in a clay surface charge distribution as schematically shown in FIG. 3. The positive-negative charge distribution over the entire clay surface provides for excellent dipole-dipole attraction of polar carbonyl-functional and/or carboxylic acid-functional monomers on the surfaces of the clay platelets.

The intercalate-containing and/or exfoliate-containing compositions can be in the form of a stable thixotropic gel that is not subject to phase separation and can be used to deliver any active materials, such as in the cosmetic, hair care and pharmaceutical industries. The layered material is intercalated and optionally exfoliated by contact with an intercalant monomer and water and then mixed and/or extruded to intercalate the monomer between adjacent phyllosilicate platelets and optionally separate (exfoliate) the layered material into individual platelets. The amount of water varies, depending upon the amount of shear imparted to the layered material in contact with the intercalant monomer and water. In one method, the intercalating composition is pug milled or extruded at a water content of about 25% by weight to about 50% by weight water, preferably about 35% to about 40% by weight water, based on the dry weight of the layered material, e.g., clay. In another method, the clay and water are slurried, with at least about 25% by weight water, preferably at least about 65% by weight water, based on the dry weight of the layered material, e.g., preferably less than about 20% by weight clay in water, based on the total weight of layered material and water, more preferably less than about 10% layered material in water, with the addition of about 2% by weight to about 90% by weight intercalant monomer, based on the dry weight of the layered material.

Sorption of the intercalant monomer should be sufficient to achieve expansion of adjacent platelets of the layered material (when measured dry) to an interlayer spacing of at least about 5 Å, preferably to a spacing of at least about 10 Å, more preferably a spacing of at least about 20 Å, and most preferably a spacing of about 30-45 Å. To achieve intercalates that can be exfoliated easily using the monomer intercalants disclosed herein, the weight ratio of intercalant monomer to layered material, preferably a water-swellable smectite clay such as sodium bentonite, in the intercalating composition should be at least about 1:20, preferably at least about 1:12 to 1:10, more preferably at least about 1:5, and most preferably about 1:5 to about 1:3. It is preferred that the concentration of intercalant monomer in the intercalating composition, based on the total weight of intercalant monomer plus intercalant carrier (water plus any non-carbonyl-functional and non-carboxylic acid-functional organic liquid solvent) in the intercalating composition is at least about 15% by weight, more preferably at least about 20% by weight intercalant monomer, for example about 20-30% to about 90% by weight intercalant monomer, based on the weight of intercalant monomer plus intercalant carrier in the intercalant composition during intercalation.

It has been found that the intercalates of the present invention are increased in interlayer spacing step-wise. If the phyllosilicate is contacted with an intercalant monomer-containing composition containing less than about 16% by weight intercalant monomer, e.g., 10% to about 15% by weight intercalant monomer, based on the dry weight of the phyllosilicate, a monolayer width of intercalant monomer is sorbed (intercalated) between the adjacent platelets of the layered material. If the phyllosilicate is contacted with an intercalating composition containing less than about 16% by weight intercalant monomer, e.g., 10% to about 15% by weight intercalant monomer, based on the dry weight of the phyllosilicate, a monolayer width of intercalant monomer is sorbed (intercalated) between the adjacent platelets of the layered material. A monolayer of intercalant monomer intercalated between platelets increases the interlayer spacing to about 5 Å to less than about 10 Å. When the amount of intercalant monomer is in the range of about 16% to less than about 35% by weight, based on the weight of the dry layered material, the intercalant monomer is sorbed in a bilayer, thereby increasing the interlayer spacing to about 10 Å to about 16 Å. At an intercalant monomer loading in the intercalant monomer-containing composition of about 35% to less than about 55% intercalant monomer, based on the dry weight of the layered material contacted, the interlayer spacing is increased to about 20 Å to about 25 Å, corresponding to three layers of intercalant monomer sorbed between adjacent platelets of the layered material. At an intercalant monomer loading of about 55% to about 80% intercalant monomer, based on the dry weight of the layered material in the intercalating composition, the interlayer spacing will be increased to about 30 Å to about 35 Å, corresponding to 4 and 5 layers of intercalant monomer sorbed (intercalated) between adjacent platelets of the layered material.

Such interlayer spacings have never been achieved by direct intercalation of the carbonyl-functional or carboxylic acid-functional intercalant monomers, without prior sorption of an onium or silane coupling agent, and provides easier and more complete exfoliation for or during incorporation of the platelets into a polar organic compound or a polar organic compound-containing composition carrier or solvent to provide unexpectedly viscous carrier compositions, for delivery of the carrier or solvent, or for administration of an active compound that is dissolved or dispersed in the carrier or solvent. Such compositions, especially the high viscosity gels, are particularly useful for delivery of active compounds, such as oxidizing agents for hair waving lotions, and drugs for topical administration, since extremely high viscosities are obtainable; and for admixtures of the platelets with polar solvents in modifying rheology, e.g., of cosmetics, oil-well drilling fluids, paints, lubricants, especially food grade lubricants, in the manufacture of oil and grease, and the like. Such intercalates also are especially useful in admixture with matrix thermoplastic or thermosetting polymers in the manufacture of polymeric articles from the polar organic carrier/polymer/intercalate and/or platelet composite materials.

Once exfoliated, the platelets of the intercalate are predominantly completely separated into individual platelets and the originally adjacent platelets no longer are retained in a parallel, spaced disposition, but are free to move as predominantly individual intercalant monomer-coated (continuously or discontinuously) platelets throughout a carrier or solvent material to maintain viscosity and thixotropy of the carrier material. The predominantly individual phyllosilicate platelets, having their platelet surfaces complexed with intercalant monomer molecules, are randomly, homogeneously and uniformly dispersed, predominantly as individual platelets, throughout the carrier or solvent to achieve new and unexpected viscosities in the carrier/platelet compositions even after addition of an active organic compound, such as a cosmetic component or a medicament, for administration of the active organic compound(s) from the composition.

As recognized, the thickness of the exfoliated, individual platelets (about 10 Å) is relatively small compared to the size of the flat opposite platelet faces. The platelets have an aspect ratio in the range of about 200 to about 2,000. Dispersing such finely divided platelet particles into a polymer melt or into a polar organic liquid carrier imparts a very large area of contact between carrier and platelet particles, for a given volume of particles in the composite, and a high degree of platelet homogeneity in the composite material. Platelet particles of high strength and modulus, dispersed at sub-micron size (nanoscale), impart greater mechanical reinforcement and a higher viscosity to a polar organic liquid carrier than do comparable loadings of conventional reinforcing fillers of micron size, and can impart lower permeability to matrix polymers than do comparable loadings of conventional fillers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a top view of sodium montmorillonite clay showing the ionic charge distribution for the sodium montmorillonite clay top and interlayer surfaces showing Na⁺ ions as the largest circles as well as magnesium and aluminum ions and Si and O atoms disposed beneath the sodium ions;

FIG. 2 is a side view (bc-projection) of the schematic representation of FIG. 1;

FIG. 3 is a schematic representation of the charge distribution on the surfaces of sodium montmorillonite clay platelets showing the distribution of positive and negative charges on the clay platelet surfaces as a result of the natural disposition of the Na, Mg, Al, Si, and O atoms of the clay shown in FIGS. 1 and 2; and

FIG. 4 is an x-ray diffraction pattern for a complex of a mixture of acrylic acid (AAC), sodium acrylate (NaAAc) and sodium montmorillonite at a weight ratio of clay to (AAc+NaAAc) of 1.9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

To form the intercalated and exfoliated materials of the present invention, the layered material, e.g., the phyllosilicate, should be swelled or intercalated by sorption of an intercalant monomer that includes a carbonyl and/or a carboxylic acid functionality. In accordance with a preferred embodiment of the present invention, the phyllosilicate should include at least 4% by weight water, up to about 5,000% by weight water, based on the dry weight of the phyllosilicate, preferably about 7% to about 100% water, more preferably about 25% to about 50% by weight water, prior to or during contact with the intercalant monomer to achieve sufficient intercalation for exfoliation. Preferably, the phyllosilicate should include at least about 4% by weight water before contact with the intercalating carrier for efficient intercalation. The amount of intercalant monomer in contact with the phyllosilicate from the intercalating composition, for efficient exfoliation, should provide an intercalant monomer/phyllosilicate weight ratio (based on the dry weight of the phyllosilicate) of at least about 1:20, preferably at least about 3.2:20, and more preferably about 4-14:20, to provide efficient sorption and complexing (intercalation) of the intercalant monomer between the platelets of the layered material, e.g., phyllosilicate.

The monomer intercalants are introduced in the form of a solid or liquid composition (neat or aqueous, with or without a non-carbonyl-functional and/or a non-carboxylic acid-functional organic solvent, e.g., an aliphatic hydrocarbon, such as heptane) having an intercalant monomer concentration of at least about 2%, preferably at least about 5% by weight intercalant monomer, more preferably at least about 50% to about 100% by weight intercalant monomer in the intercalating composition, based on the dry weight of the layered material, for intercalant monomer sorption. The intercalant monomer can be added as a solid with the addition to the layered material/intercalant monomer blend of about 20% water, preferably at least about 30% water to about 5,000% water or more, based on the dry weight of layered material. Preferably about 30% to about 50% water, more preferably about 30% to about 40% by weight water, based on the dry weight of the layered material is included in the intercalating composition when extruding or pug milling, so that less water is sorbed by the intercalate, thereby necessitating less drying energy after intercalation. The monomer intercalants may be introduced into the spaces between every layer, nearly every layer, or at least a predominance of the layers of the layered material such that the subsequently exfoliated platelet particles are preferably, predominantly less than about 5 layers in thickness; more preferably, predominantly about 1 or 2 layers in thickness; and most preferably, predominantly single platelets.

Any swellable layered material that sufficiently sorbs the intercalant monomer to increase the interlayer spacing between adjacent phyllosilicate platelets to at least about 10 Å(when the phyllosilicate is measured dry) may be used in the practice of this invention. Useful swellable layered materials include phyllosilicates, such as smectite clay minerals, e.g., montmorillonite, particularly sodium montmorillonite; magnesium montmorillonite and/or calcium montmorillonite; nontronite; beidellite; volkonskoite; hectorite; saponite; sauconite; sobockite; stevensite; svinfordite; vermiculite; and the like. Other useful layered materials include micaceous minerals, such as illite and mixed layered illite/smectite minerals, such as rectorite, tarosovite, ledikite and admixtures of illites with the clay minerals named above.

Other layered materials having little or no charge on the layers may be useful in this invention provided they can be intercalated with the intercalant monomers to expand their interlayer spacing to at least about 5 Å, preferably at least about 10 Å. Preferred swellable layered materials are phyllosilicates of the 2:1 type having a negative charge on the layers ranging from about 0.15 to about 0.9 charges per formula unit and a commensurate number of exchangeable metal cations in the interlayer spaces. Most preferred layered materials are smectite clay minerals such as montmorillonite, nontronite, beidellite, volkonskoite, hectorite, saponite, sauconite, sobockite, stevensite, and svinfordite.

As used herein the "interlayer spacing" refers to the distance between the internal faces of the adjacent layers as they are assembled in the layered material before any delamination (exfoliation) takes place. The interlayer spacing is measured when the layered material is "air dry", e.g., contains 3-10% by weight water, preferably about 3-6% by weight water, e.g., 5% by weight water based on the dry weight of the layered material. The preferred clay materials generally include interlayer cations such as Na⁺, Ca⁺², K⁺, Mg⁺², NH₄ ⁺ and the like, including mixtures thereof.

The amount of intercalant monomer intercalated into the swellable layered materials useful in this invention, in order that the intercalated layered material platelet surfaces sufficiently complex with the intercalant monomer molecules such that the layered material may be easily exfoliated or delaminated into individual platelets, may vary substantially between about 10% and about 90%, based on the dry weight of the layered silicate material. In the preferred embodiments of the invention, amounts of monomer intercalants employed, with respect to the dry weight of layered material being intercalated, will preferably range from about 8 grams of intercalant monomer:100 grams of layered material (dry basis), preferably at least about 10 grams of intercalant monomer:100 grams of layered material to about 80-90 grams intercalant monomer:100 grams of layered material. More preferred amounts are from about 20 grams intercalant monomer/100 grams of layered material to about 60 grams intercalant monomer/100 grams of layered material (dry basis).

The monomer intercalants are introduced into (sorbed within) the interlayer spaces of the layered material in one of two ways. In a preferred method of intercalating, the layered material is intimately mixed, e.g., by extrusion or pug milling, to form an intercalating composition comprising the layered material, in an intercalant monomer/water solution, or intercalant monomer, water and an organic carrier for the carbonyl-functional or carboxylic acid-functional intercalant monomer. To achieve sufficient intercalation for exfoliation, the layered material/intercalant monomer blend contains at least about 8% by weight, preferably at least about 10% by weight intercalant monomer, based on the dry weight of the layered material. The intercalant monomer carrier (preferably water, with or without an organic solvent) can be added by first solubilizing or dispersing the intercalant monomer in the carrier; or a dry intercalant monomer and relatively dry phyllosilicate (preferably containing at least about 4% by weight water) can be blended and the intercalating carrier added to the blend, or to the phyllosilicate prior to adding the dry intercalant monomer. In every case, it has been found that surprising sorption and complexing of intercalant monomer between platelets is achieved at relatively low loadings of intercalating carrier, especially H₂ O, e.g., at least about 4% by weight water, based on the dry weight of the phyllosilicate. When intercalating the phyllosilicate in slurry form (e.g., 900 pounds water, 100 pounds phyllosilicate, 25 pounds intercalant monomer) the amount of water can vary from a preferred minimum of at least about 30% by weight water, with no upper limit to the amount of water in the intercalating composition (the phyllosilicate intercalate is easily separated from the intercalating composition).

Alternatively, the intercalating carrier, e.g., water, with or without an organic solvent, can be added directly to the phyllosilicate prior to adding the intercalant monomer, either dry or in solution. Sorption of the monomer intercalant molecules may be performed by exposing the layered material to dry or liquid intercalant monomers in the intercalating composition containing at least about 2% by weight, preferably at least about 5% by weight intercalant monomer, more preferably at least about 50% intercalant monomer, based on the dry weight of the layered material. Sorption may be aided by exposure of the intercalating composition to heat, pressure, ultrasonic cavitation, or microwaves.

In accordance with another method of intercalating the intercalant monomer between the platelets of the layered material and exfoliating the intercalate, the layered material, containing at least about 4% by weight water, preferably about 10% to about 15% by weight water, is blended with an aqueous solution of an intercalant monomer in a ratio sufficient to provide at least about 8% by weight, preferably at least about 10% by weight intercalant monomer, based on the dry weight of the layered material. The blend then preferably is extruded for faster intercalation of the intercalant monomer with the layered material.

The intercalant monomer has an affinity for the phyllosilicate so that it is sorbed between, and is maintained associated with the surfaces of the silicate platelets, in the interlayer spaces, and after exfoliation. In accordance with the present invention, the intercalant monomer should include a carbonyl and/or a carboxylic acid functionality to be sufficiently bound, it is hereby theorized, by a mechanism selected from the group consisting of ionic complexing; electrostatic complexing; chelation; hydrogen bonding; dipole/dipole; Van Der Waals forces; and any combination thereof. Such bonding, via the metal cations of the phyllosilicate sharing electrons with two oxygen atoms from a carbonyl or a carboxylic acid (or salt) functionality of one intercalant monomer molecule or of two adjacent intercalant monomer molecules, to an inner surface of the phyllosilicate platelets provides adherence between the carbonyl functionality and/or carboxylic acid functionality and the platelet inner surfaces of the layered material. Such intercalant monomers have sufficient affinity for the phyllosilicate platelets to maintain sufficient interlayer spacing for exfoliation, without the need for coupling agents or spacing agents, such as the onium ion or silane coupling agents disclosed in the above-mentioned prior art.

As shown in FIGS. 1-3, the disposition of surface Na⁺ ions with respect to the disposition of O, Mg, Si, and Al atoms, and the natural clay substitution of Mg⁺² cations for Al⁺³ cations, leaving a net negative charge at the sites of substitution, results in a clay surface charge distribution as shown in FIG. 3. This alternating positive to negative surface charge over spans of the clay platelets surfaces, and on the clay platelet surfaces in the interlayer spacing, provide for excellent dipole-dipole attraction of polar carbonyl-functional and/or carboxylic acid-functional monomeric molecules for intercalation of the clay and for bonding of such polar molecules on the platelet surfaces, after exfoliation.

It is preferred that the platelet loading be less than about 10%. Platelet particle loadings within the range of about 0.05% to about 40% by weight, preferably about 0.5% to about 20%, more preferably about 1% to about 10% of the composite material significantly enhances viscosity. In general, the amount of platelet particles incorporated into a liquid carrier, such as a polar solvent, e.g., a glycol such as glycerol, is less than about 90% by weight of the mixture, and preferably from about 0.01% to about 80% by weight of the composite material mixture, more preferably from about 0.05% to about 40% by weight of the mixture, and most preferably from about 0.05% to about 20% or 0.05% to about 10% by weight.

In accordance with an important feature of the present invention, the intercalated phyllosilicate can be manufactured in a concentrated form, e.g., 10-90%, preferably 20-80% intercalant monomer with or without another polar organic compound carrier and 10-90%, preferably 20-80% intercalated phyllosilicate that can be dispersed in the polar organic carrier and exfoliated before or after addition to the carrier to a desired platelet loading.

Polar organic compounds containing one or more carbonyl or carboxylic acid functionalities, including compounds having carboxylic acid, aldehyde, and/or ketone functionalities, are suitable for use as intercalate monomers and/or as the polar organic liquid carrier (matrix monomer) in accordance with the present invention. The carbonyl-functional compounds include all carboxylic acids, including the straight chain alkanoic acids (C_(n) H_(2n) O₂); fatty carboxylic acids, including the polyunsaturated fatty acids and the acetylenic fatty acids; substituted carboxylic acids and fatty carboxylic acids with alicyclic substituents; as well as the oleo-based carboxylic acids; branched-chain carboxylic acids and the trialkylacetic acids. Other suitable carbonyl-functional polar organic compounds include the aldehydes and ketones.

The preferred carbonyl-functional polar organic monomer intercalants are the carboxylic acids and their derivatives. Examples of suitable carboxylic acids and derivatives thereof include:

REPRESENTATIVE STRAIGHT-CHAIN ALKANOIC ACIDS, C_(n) H_(2n) O₂ SYSTEMATIC NAME (COMMON NAME)

Methanoic (formic); ethanoic (acetic); propanoic (propionic); butanoic (butyric); pentanoic (valeric); hexanoic ( caproic!); heptanoic ( enanthic!); octanoic ( caprylic!); nonanoic (pelargonic); decanoic ( capric!); undecanoic ( undecylic!); dodecanoic (lauric); tridecanoic ( tridecylic!); tetradecanoic (myristic); pentadecanoic ( pentadecylic!); hexadecanoic (palmitic); heptadecanoic (margaric); octadecanoic (stearic); nonadecanoic ( nonadecyclic!); eicosanoic (arachidic); docosanoic (behenic); tetracosanoic (lignoceric); hexacosanoic (cerotic); octacosanoic (montanic); triacontanoic (melissic); tritriacontanoic (psyllic); and pentatriacontanoic (ceroplastic).

REPRESENTATIVE STRAIGHT-CHAIN ALKENOIC ACIDS, C_(n) H.sub.(2n-2) O₂ SYSTEMATIC NAME (COMMON NAME)

Propenoic (acrylic); trans-2-butenoic (crotonic); cis-2-butenoic (isocrotonic); 3-butenoic (vinylacetic); 2-pentenoic (β-ethylacrylic); 3-pentenoic (β-pentenoic); 4-pentenoic (allylacetic); 2-hexenoic (isohydroascorbic); 3-hexenoic (hydrosorbic); trans-2-heptenoic; 2-octenoic; 2-nonenoic; trans-4-decenoic; cis-4-decenoic; 9-decenoic (caproleic); 10-undecenoic (undecylenic); trans-3-dodecenoic (linderic); tridecenoic; cis-9-tetradecenoic (myristoleic); pentadecenoic; cis-9-hexadecenoic (cis-9-palmitoleic); trans-9-hexadecenoic (trans-9-palmitoleic); 9-heptadecenoic; cis-6-octadecenoic (petroselinic); trans-6-octadecenoic (petroselaidic); cis-9-octadecenoic (oleic); trans-9-octadecenoic (elaidic); cis-11-octadecenoic; trans-11-octadecenoic (vaccenic); cis-5-eicosenoic; cis-9-eicosenoic (gadoleic); cis-11-docosenoic (cetoleic); cis-13 docosenoic (erucic); trans-13-docosenoic (brassidic); cis-15-tetracosenoic (selacholeic); cis-17-hexacosenoic (ximenic); and cis-21-triacontenoic (lumequeic).

REPRESENTATIVE POLYUNSATURATED FATTY ACIDS SYSTEMATIC NAME (COMMON NAME) REPRESENTATIVE DIENOIC ACIDS, C_(n) H_(2n-4) O₂

2,4-pentadienoic (β-vinylacrylic); 2,4-hexadienoic (sorbic); trans-2,4-decadienoic, trans-2,4-dodecadienoic; cis-9, cis-12-octadecadienoic (linoleic); trans-9, trans-12-octadecadienoic (linolelaidic); 5,6-octadecadienoic (laballenic); and 5,13-docosadienoic.

REPRESENTATIVE TRIENOIC ACIDS, C_(n) H_(2n-6) O₂

6,10,14-hexadecatrienoic (hiragonic); cis-9,cis-12,cis-15-octadecatrienoic (linolenic); cis-9,trans-11,trans-13-octadecatrienoic (α-eleostearic); trans-9,trans-11,trans-13-octadecatrienoic (β-eleostearic); cis-9,cis-11,trans-13-octadecatrienoic (punicic); and trans-9,trans-12,trans-15-octadecatrienoic (linolenelaidic).

REPRESENTATIVE TETRAENOIC ACIDS, C_(n) H_(2N-8) O₂

4,8,12,15 octadecatetraenoic (moroctic); cis-9,trans-11,trans-13,cis-15-octadecatetraenoic (α-parinaric); trans-9,trans-11,trans-13,trans-15-octadecatetraenoic (β-parinaric); and 5,8,11,14-eicosatetraenoic (arachidonic).

REPRESENTATIVE PENTAENOIC ACIDS, C_(n) H_(2N-10) O₂

4,8,12,15,19-docosapentaenoic (clupanodonic).

REPRESENTATIVE SUBSTITUTED ACIDS SYSTEMATIC NAME (COMMON NAME)

2-methylpropenoic (methacrylic); 2-methylpropanoic (isobutyric); 2-methyl-cis-2-butenoic (angelic); 2-methyl-trans-2-butenoic (tiglic); 3-methyl-2-butenoic (β,β-dimethyl acrylic); 2-methylbutanoic; 3-methylbutanoic (isovaleric); 2,2-dimethylpropanoic (pivalic); 2-ethylhexanoic; 3,11-dihydroxytetradecanoic (ipurolic); 2,15,16-trihydroxyhexadecanoic (ustilic); 9,10,16-trihydroxyhexadecanoic (aleuritic); 16-hydroxy-7-hexadecenoic (ambrettolic); 12-hydroxy-cis-9-octadecenoic (ricinoleic); 12-hydroxy- trans-9-octadecenoic (ricinelaidic); 4-oxo-9,11,13-octadecatrienoic (licanic); 9,10-dihydroxyoctadecanoic; 12-hydroxyoctadecanoic; 12-oxooctadecanoic; 18-hydroxy-9,11,13-octadecatrienoic (kamlolenic); 12,13-epoxy-cis-9-octadecenoic (vernolic); 8-hydroxy-trans-11-octadecene-9-ynoic (ximenynolic); 8-hydroxy-17-octadecene-9,11-diynoic (isanolic); and 14-hydroxy-cis-11-eicosenoic (lesquerolic).

REPRESENTATIVE FATTY ACIDS WITH ALICYCLIC SUBSTITUENTS (COMMON NAME) REPRESENTATIVE CYCLOPENTENYL COMPOUNDS

Aleprolic; aleprestic; aleprylic; alepric; hydnocarpic; and chaulmoogric.

REPRESENTATIVE CYCLOPROPENYL COMPOUNDS

Malvalic (halphenic); sterculic; and lactobacillic.

    ______________________________________                                         REPRESENTATIVE OLEO-BASED CARBOXYLIC ACIDS AND                                 USES                                                                           ACID              USES                                                         ______________________________________                                         canola            surfactants                                                  castor oil acids (ricinoleic,                                                                    lubricating greases                                          12-hydroxystearic)                                                             coconut oil acids surfactants, soap                                            hydrogenated and/or separated                                                                    metallic stearates (plastic                                  tallow-based acids                                                                               lubricants), tires, candles,                                                   crayons, cosmetics                                           soybean oil acids alkyd resins (paint)                                         tall oil acids    alkyd resins, ore flotation                                  2% or more rosin                                                               less than 2% tallow                                                                              soap, lubricants, fabric                                     fatty acids       softeners, asphalt                                                             emulsifiers, synthetic rubber,                                                 plastics                                                     capric            synthetic lubricants,                                                          medium-chain triglycerides                                   caprylic          synthetic lubricants,                                                          medium-chain triglycerides                                   caprylic-capric blend                                                                            synthetic lubricants,                                                          medium-chain triglycerides                                   lauric, 95% (dodecanoic)                                                                         surfactants, soap                                            myristic, 95% (tetradecanoic)                                                                    esters for cosmetics, lotions                                oleic             surfactants, lubricants,                                                       plasticizers                                                 palmitic, 90%     esters for personal care                                                       products                                                     pelargonic (nonanoic)                                                                            synthetic lubricants,                                        stearic, 90%      plasticizers, alkyd resins,                                                    ore flotation                                                ______________________________________                                    

REPRESENTATIVE BRANCHED-CHAIN ACIDS (COMMON NAME)

2-methylpropanoic (isobutyric); 2-methylbutanoic (isopentanoic); 3-methylbutanoic (isovaleric); 2,2-dimethylpropanoic (neopentanoic); 2-ethylhexanoic; mixed isomers (isononanoic); 2,2-dimethyloctanoic (neodecanoic); and mixed isomers (isostearic).

TRIALKYLACETIC ACIDS

Trialkylacetic acids are characterized by the following structure: ##STR1## in which R, R', and R" are C_(x) H_(2x+1), with x≧1. The lowest member of the series (R=R'=R"=CH₃) is the C₅ acid, trimethylacetic acid or 2,2-dimethylpropanoic acid (also, neopentanoic acid, pivalic acid). For higher members in the series, the products are typically mixtures of isomers, resulting from the use of mixed isomer feedstocks and the chemical rearrangements that occur in the manufacturing process.

The trialkylacetic acids have a number of uses in areas such as polymers, pharmaceuticals, agricultural chemicals, cosmetics, and metal-working fluids. Commercially important derivatives of these acids include acid chlorides, peroxyesters, metal salts, vinyl esters, and glycidyl esters.

The C₁₀ trialkylacetic acids, referred to as neodecanoic acid or as Versatic 10, are liquids at room temperature. Typical physical properties for commercially available material are given in Table 2. These materials are typically mixtures of isomers.

Metal salts of neodecanoic acid have also been used as catalysts in the preparation of polymers. For example, bismuth, calcium, barium, and zirconium neodecanoates have been used as catalysts in the formation of polyurethane elastomers. Magnesium neodecanoate is one component of a catalyst system for the preparation of polyolefins; vanadium, cobalt, copper, or iron neodecanoates have been used as curing catalysts for conjugated-diene butyl elastomers.

The metal salts of neodecanoic acid have found wide usage as driers for paints and inks. Metal neodecanoates that are used include silver, cobalt and zirconium, along with lead, copper, manganese, and zinc.

Neodecanoic acid is also used as the carrier for metals in poly(vinyl chloride) heat stabilizers. Metals used in this application include barium, cadmium, and zinc. Tin as the neodecanoate salt has also been claimed as a heat stabilizer for maleic anhydride.

ADHESION PROMOTERS

One of the growing uses for neodecanoic acid has been in the preparation of adhesion promoters for radial tires. In this application, cobalt or nickel neodecanoate, along with other components, is used during tire manufacture to promote the adhesion or bonding of the rubber to the steel cord. The result is high adhesive strength, good thermal aging resistance and improved resistance to moisture aging.

Neodecanoic acid and its esters are used in cosmetics as emollients, emulsifiers, and solubilizers. Zinc or copper salts of neoacids are used as preservatives for wood.

ALDEHYDES

Representative aldehydes suitable as the intercalant monomer and/or as the polar organic carrier in accordance with the present invention include the following:

Formaldehyde; acetaldehyde; propionaldehyde; butanal (n-butyraldehyde); 2-methylpropanal (isobutyraldehyde); pentanal (n-valeraldehyde); 3-methylbutanal (isovaleraldehyde); hexanal (caproaldehyde); benzaldehyde; heptanal (heptaldehyde); octanal (caprylaldehyde); phenylacetaldehyde; o-tolualdehyde; m-tolualdehyde; p-tolualdehyde; salicylaldehyde (o-hydroxybenzaldehyde); p-hydroxybenzaldehyde (4-formylphenol); and p-anisaldehyde (p-methoxybenzaldehyde).

USES

Aldehydes find the most widespread use as chemical intermediates. The production of acetaldehyde, propionaldehyde, and butyraldehyde as precursors of the corresponding alcohols and acids are examples. The aldehydes of low molecular weight are also condensed in an aldol reaction to form derivatives which are important intermediates for the plasticizer industry. As mentioned earlier, 2-ethylhexanol, produced from butyraldehyde, is used in the manufacture of di(2-ethylhexyl) phthalate. Aldehydes are also used as intermediates for the manufacture of solvents (alcohols and ethers), resins, and dyes. Isobutyraldehyde is used as a intermediate for production of primary solvents and rubber antioxidants. Fatty aldehydes C₈ -C₁₃ are used in nearly all perfume types and aromas. Polymers and copolymers of aldehydes exist and are of commercial significance.

KETONES

Suitable ketones are the organic compounds that contain one or more carbonyl groups bound to two aliphatic, aromatic, or alicyclic substituents, and are represented by the general formula ##STR2##

Representative ketones, including the aliphatic ketones; diketones; cyclic ketones; and aromatic ketones, are as follows:

SYSTEMATIC NAME (TRIVIAL OR COMMON NAME)

2-propanone (acetone); 2-butanone (methyl ethyl ketone); 2-pentanone (methyl propyl ketone); 3-methyl-2-butanone (methyl isopropyl ketone); 4-methyl-2-pentanone (methyl isobutyl ketone); 2-hexanone (methyl n-butyl ketone); 3-methyl-2-pentanone (methyl sec-butyl ketone); 3,3-dimethyl-2-butanone (pinacolone); 2-heptanone (methyl amyl ketone); 5-methyl-2-hexanone (methyl isoamyl ketone); 2-octanone (methyl hexyl ketone); 4-hydroxy-4-methyl-2-pentanone (diacetone alcohol); 3-pentanone (diethyl ketone); 2,4-dimethyl-3-pentanone (diisopropyl ketone); 2,6-dimethyl-4-heptanone (diisobutyl ketone); 3-hexanone (ethyl propyl ketone); 3-heptanone (butyl ethyl ketone); 3-octanone (ethyl amyl ketone); 2,6,8-trimethyl-4-nonanone (isobutyl heptyl ketone); 3-buten-2-one (methyl vinyl ketone); 3-methyl-2-buten-2-one (methyl isopropenyl ketone); 4-methyl-3-penten-2-one (mesityl oxide); 4-methyl-4-penten-2-one (isomesityl oxide); 3,5,5-trimethyl-2-cyclohexen-1-one (isophorone); 3,5,5-trimethyl-3-cyclohexen-1-one (β-isophorone); 2,3-butanedione (diacetyl); 2,3-pentanedione; 2,4-pentanedione (acetylacetone); 2,5-hexanedione; cyclopentanone (adipic ketone); cyclohexanone (pimelic ketone); cycloheptanone; 3,3,5-trimethylcyclohexanone; acetophenone (methyl phenyl ketone); benzophenone (diphenyl ketone); 1-phenyl-2-propanone (phenylacetone); and propiophenone (phenyl ethyl ketone).

REPRESENTATIVE 1,2-DIKETONES

2,3-pentanedione; 2,3-hexanedione; 3,4-hexanedione; 4-methyl-2,3-pentanedione; 3,4-heptanedione; 5-methyl-2,3-hexanedione; 2,3-octanedione; 4,5-octanedione; 2,5-dimethyl-3,4-heptanedione; 5-methyl-3,4-heptanedione; 6-methyl-3,4-heptanedione; 1,2-cyclopentanedione; 1,2-cyclohexanedione; benzil; 1-phenyl-1,2-propanedione; and 1,2-naphthalendione.

REPRESENTATIVE 1,3-DIKETONES

2,4-hexanedione; 3,5-heptanedione; 2,4-heptanedione; 3,5-octanedione; 5-methyl-2,4-hexanedione; 2,6-dimethyl-3,5-heptanedione; 2,4-octanedione; 5,5-dimethyl-2,4-hexanedione; 6-methyl2,4-heptanedione; 1,3-cyclopentanedione; 1,3-cyclohexanedione; 5,5-dimethyl-1,3-cyclohexanedione; 1-phenyl-1,3-butanedione; 1-phenyl-1,3-pentanedione; 1,3-diphenyl-1,3-propanedione; and 1-phenyl-2,4-pentanedione.

REPRESENTATIVE CYCLIC KETONES, (CH₂)_(x) C═O

Cyclopropanone; cyclobutanone; cyclopentanone; cyclohexanone; cycloheptanone; cyclooctanone; cyclononanone; cyclodecanone; cycloundecanone; cyclododecanone; cyclotridecanone; cyclotetradecanone; cyclopentadecanone; cyclohexadecanone; cycloheptadecanone; cyclooctadecanone; cyclononadecanone; and cyclocosanone.

REPRESENTATIVE AROMATIC KETONES

Aromatic ketones of industrial significance include acetophenone, propiophenone, and benzophenone.

In accordance with another embodiment of the present invention, the intercalates can be exfoliated and dispersed into one or more melt-processible thermoplastic and/or thermosetting matrix oligomers or polymers, or mixtures thereof. Matrix polymers for use in this embodiment of the process of this invention may vary widely, the only requirement is that they are melt processible. In this embodiment of the invention, the polymer includes at least ten (10), preferably at least thirty (30) recurring monomeric units. The upper limit to the number of recurring monomeric units is not critical, provided that the melt index of the matrix polymer under use conditions is such that the matrix polymer forms a flowable mixture. Most preferably, the matrix polymer includes from at least about 10 to about 100 recurring monomeric units. In the most preferred embodiments of this invention, the number of recurring units is such that the matrix polymer has a melt index of from about 0.01 to about 12 grams per 10 minutes at the processing temperature.

Thermoplastic resins and rubbers for use as matrix polymers in the practice of this invention may vary widely. Illustrative of useful thermoplastic resins, which may be used alone or in admixture, are polylactones such as poly(pivalolactone), poly(caprolactone) and the like; polyurethanes derived from reaction of diisocyanates such as 1,5-naphthalene diisocyanate; p-phenylene diisocyanate, m-phenylene diisocyanate, 2,4-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate, 3,3'-dimethyl-4,4'-biphenyl diisocyanate, 4,4'-diphenylisopropylidene diisocyanate, 3,3'-dimethyl-4,4'-diphenyl diisocyanate, 3,3'-dimethyl-4,4'-diphenylmethane diisocyanate, 3,3'-dimethoxy-4,4'-biphenyl diisocyanate, dianisidine diisocyanate, toluidine diisocyanate, hexamethylene diisocyanate, 4,4'-diisocyanatodiphenylmethane and the like and linear long-chain diols such as poly(tetramethylene adipate), poly(ethylene adipate), poly(1,4-butylene adipate), poly(ethylene succinate), poly(2,3-butylene succinate), polyether diols and the like; polycarbonates such as poly methane bis(4-phenyl) carbonate!, poly 1,1-ether bis(4-phenyl) carbonate!, poly diphenylmethane bis(4-phenyl)carbonate!, poly 1,1-cyclohexane bis(4-phenyl)carbonate! and the like; polysulfones; polyethers; polyketones; polyamides such as poly(4-amino butyric acid), poly(hexamethylene adipamide), poly(6-aminohexanoic acid), poly(m-xylylene adipamide), poly(p-xylylene sebacamide), poly(2,2,2-trimethyl hexamethylene terephthalamide), poly(metaphenylene isophthalamide) (NOMEX), poly(p-phenylene terephthalamide) (KEVLAR), and the like; polyesters such as poly(ethylene azelate), poly(ethylene-1,5-naphthalate, poly(1,4-cyclohexane dimethylene terephthalate), poly(ethylene oxybenzoate) (A-TELL), poly(para-hydroxy benzoate) (EKONOL), poly(1,4-cyclohexylidene dimethylene terephthalate) (KODEL) (as), poly(1,4-cyclohexylidene dimethylene terephthalate) (Kodel) (trans), polyethylene terephthalate, polybutylene terephthalate and the like; poly(arylene oxides) such as poly(2,6-dimethyl-1,4-phenylene oxide), poly(2,6-diphenyl-1,4-phenylene oxide) and the like; poly(arylene sulfides) such as poly(phenylene sulfide) and the like; polyetherimides; vinyl polymers and their copolymers such as polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride; polyvinyl butyral, polyvinylidene chloride, ethylene-vinyl acetate copolymers, and the like; polyacrylics, polyacrylate and their copolymers such as polyethyl acrylate, poly(n-butyl acrylate), polymethylmethacrylate, polyethyl methacrylate, poly(n-butyl methacrylate), poly(n-propyl methacrylate), polyacrylamide, polyacrylonitrile, polyacrylic acid, ethylene-acrylic acid copolymers, ethylene-vinyl alcohol copolymers acrylonitrile copolymers, methyl methacrylate-styrene copolymers, ethylene-ethyl acrylate copolymers, methacrylated butadiene-styrene copolymers and the like; polyolefins such as low density poly(ethylene), poly(propylene), chlorinated low density poly(ethylene), poly(4-methyl-1-pentene), poly(ethylene), poly(styrene), and the like; ionomers; poly(epichlorohydrins); poly(urethane) such as the polymerization product of diols such as glycerin, trimethylol-propane, 1,2,6-hexanetriol, sorbitol, pentaerythritol, polyether polyols, polyester polyols and the like with a, polyisocyanate such as 2,4-tolylene diisocyanate, 2,6-tolylene diisocyante, 4,4'-diphenylmethane diisocyanate, 1,6-hexamethylene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate and the like; and polysulfones such as the reaction product of the sodium salt of 2,2-bis(4-hydroxyphenyl) propane and 4,4'-dichlorodiphenyl sulfone; furan resins such as poly(furan); cellulose ester plastics such as cellulose acetate, cellulose acetate butyrate, cellulose propionate and the like; silicones such as poly(dimethyl siloxane), poly(dimethyl siloxane), poly(dimethyl siloxane co-phenylmethyl siloxane), and the like; protein plastics; and blends of two or more of the foregoing.

Vulcanizable and thermoplastic rubbers useful as matrix polymers in the practice of this embodiment of the invention may also vary widely. Illustrative of such rubbers are brominated butyl rubber, chlorinate butyl rubber, polyurethane elastomers, fluoroelastomers, polyester elastomers, polyvinylchloride, butadiene/acrylonitrile elastomers, silicone elastomers, poly(butadiene), poly(isobutylene), ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, sulfonated ethylene-propylene-diene terpolymers, poly(chloroprene), poly(2,3-dimethylbutadiene), poly(butadiene-pentadiene), chlorosulphonated poly(ethylenes), poly(sulfide) elastomers, block copolymers, made up of segments of glassy or crystalline blocks such as poly(styrene), poly(vinyl-toluene), poly(t-butyl styrene), polyesters and the like and the elastomeric blocks such as poly(butadiene), poly(isoprene), ethylene-propylene copolymers, ethylene-butylene copolymers, polyether and the like as for example the copolymers in poly(styrene)-poly(butadiene)-poly(styrene) block copolymer manufactured by Shell Chemical Company under the trade name KRATONE®.

Useful thermosetting resins useful as matrix polymers include, for example, the polyamides; polyalkylamides; polyurethanes; polycarbonates; polyepoxides; and mixtures thereof.

Most preferred thermoplastic polymers for use as a matrix polymer are thermoplastic polymers such as polyamides, polyesters, and polymers of alpha-beta unsaturated monomers and copolymers. Polyamides which may be used in the process of the present invention are synthetic linear polycarbonamides characterized by the presence of recurring carbonamide groups as an integral part of the polymer chain which are separated from one another by at least two carbon atoms. Polyamides of this type include polymers, generally known in the art as nylons, obtained from diamines and dibasic acids having the recurring unit represented by the general formula:

    --NHCOR.sup.13 COHNR.sup.14 --

in which R¹³ is an alkylene group of at least 2 carbon atoms, preferably from about 2 to about 11, or arylene having at least about 6 carbon atoms, preferably about 6 to about 17 carbon atoms; and R¹⁴ is selected from R¹³ and aryl groups. Also, included are copolyamides and terpolyamides obtained by known methods, for example, by condensation of hexamethylene diamine and a mixture of dibasic acids consisting of terephthalic acid and adipic acid. Polyamides of the above description are well-known in the art and include, for example, the copolyamide of 30% hexamethylene diammonium isophthalate and 70% hexamethylene diammonium adipate, poly(hexamethylene adipamide) (nylon 6,6), poly(hexamethylene sebacamide) (nylon 6, 10), poly(hexamethylene isophthalamide), poly(hexamethylene terephthalamide), poly(heptamethylene pimelamide) (nylon 7,7), poly(octamethylene suberamide) (nylon 8,8), poly(nonamethylene azelamide) (nylon 9,9) poly(decamethylene azelamide) (nylon 10,9), poly(decamethylene sebacamide) (nylon 10,10), poly bis(4-amino cyclohexyl)methane-1,10-decane-carboxamide)!, poly(m-xylene adipamide), poly(p-xylene sebacamide), poly(2,2,2-trimethyl hexamethylene terephthalamide), poly(piperazine sebacamdie), poly(p-phenylene terephthalamide), poly(methaphenylene isophthalamide) and the like.

Other useful polyamides for use as a matrix polymer are those formed by polymerization of amino acids and derivatives thereof, as, for example, lactams. Illustrative of these useful polyamides are poly(4-aminobutyric acid) (nylon 4), poly(6-aminohexanoic acid) (nylon 6), poly(7-aminoheptanoic acid) (nylon 7), poly(8-aminooctanoic acid) (nylon 8), poly(9-aminononanoic acid) (nylon 9), poly(10-aminodecanoic acid) (nylon 10), poly(11-aminoundecanoic acid) (nylon 11), poly(12-aminododecanoic acid) (nylon 12) and the like.

Preferred polyamides for use as a matrix polymer are poly(caprolactam), poly(12-aminododecanoic acid) and poly(hexamethylene adipamide).

Other matrix or host polymers which may be employed in admixture with exfoliates to form nanocomposites are linear polyesters. The type of polyester is not critical and the particular polyesters chosen for use in any particular situation will depend essentially on the physical properties and features, i.e., tensile strength, modulus and the like, desired in the final form. Thus, a multiplicity of linear thermoplastic polyesters having wide variations in physical properties are suitable for use in admixture with exfoliated layered material platelets in manufacturing nanocomposites in accordance with this invention.

The particular polyester chosen for use as a matrix polymer can be a homo-polyester or a co-polyester, or mixtures thereof, as desired. Polyesters are normally prepared by the condensation of an organic dicarboxylic acid and an organic diol, and, the reactants can be added to the intercalates, or exfoliated intercalates for in situ polymerization of the polyester while in contact with the layered material, before or after exfoliation of the intercalates.

Polyesters which are suitable for use as matrix polymers in this embodiment of the invention are those which are derived from the condensation of aromatic, cycloaliphatic, and aliphatic diols with aliphatic, aromatic and cycloaliphatic dicarboxylic acids and may be cycloaliphatic, aliphatic or aromatic polyesters.

Exemplary of useful cycloaliphatic, aliphatic and aromatic polyesters which can be utilized as matrix polymers in the practice of this embodiment of the invention are poly(ethylene terephthalate), poly(cyclohexylenedimethylene terephthalate), poly(ethylene dodecate), poly(butylene terephthalate), poly ethylene(2,7-naphthalate)!, poly(methaphenylene isophthalate), poly(glycolic acid), poly(ethylene succinate), poly(ethylene adipate), poly(ethylene sebacate), poly(decamethylene azelate), poly(ethylene sebacate), poly(decamethylene adipate), poly(decamethylene sebacate), poly(dimethylpropiolactone), poly(parahydroxybenzoate) (EKONOL), poly(ethylene oxybenzoate) (A-tell), poly(ethylene isophthalate), poly(tetramethylene terephthalate, poly(hexamethylene terephthalate), poly(decamethylene terephthalate), poly(1,4-cyclohexane dimethylene terephthalate) (trans), poly(ethylene 1,5-naphthalate), poly(ethylene 2,6-naphthalate), poly(1,4-cyclohexylidene dimethylene terephthalate), (KODEL) (cis), and poly(1,4-cyclohexylidene dimethylene terephthalate (KODEL) (trans).

Polyester compounds prepared from the condensation of a diol and an aromatic dicarboxylic acid are especially suitable as matrix polymers in accordance with this embodiment of the present invention. Illustrative of such useful aromatic carboxylic acids are terephthalic acid, isophthalic acid and a o-phthalic acid, 1,3-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 4,4'-diphenyldicarboxylic acid, 4,4'-diphenylsulfone-dicarboxylic acid, 1,1,3-trimethyl-5-carboxy-3-(p-carboxyphenyl)-idane, diphenyl ether 4,4'-dicarboxylic acid, bis-p(carboxyphenyl) methane and the like. Of the aforementioned aromatic dicarboxylic acids, those based on a benzene ring (such as terephthalic acid, isophthalic acid, orthophthalic acid) are preferred for use in the practice of this invention. Among these preferred acid precursors, terephthalic acid is particularly preferred acid precursor.

The most preferred matrix polymer for incorporation with exfoliates manufactured in accordance with the present invention is a polymer selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate), poly(1,4-cyclohexane dimethylene terephthalate), a polyvinylimine, and mixture thereof. Among these polyesters of choice, poly(ethylene terephthalate) and poly(butyleneterephthalate) are most preferred.

Still other useful thermoplastic homopolymers and copolymer matrix polymers for forming nanocomposites with the exfoliates of the present invention are polymers formed by polymerization of alpha-beta-unsaturated monomers or the formula:

    R.sup.15 R.sup.16 C═CH.sub.2

wherein:

R¹⁵ and R¹⁶ are the same or different and are cyano, phenyl, carboxy, alkylester, halo, alkyl, alkyl substituted with one or more chloro or fluoro, or hydrogen. Illustrative of such preferred homopolymers and copolymers are homopolymers and copolymers of ethylene, propylene, vinyl alcohol, acrylonitrile, vinylidene chloride, esters of acrylic acid, esters of methacrylic acid, chlorotrifluoroethylene, vinyl chloride and the like. Preferred are poly(propylene), propylene copolymers, poly(ethylene) and ethylene copolymers. More preferred are poly(ethylene) and poly(propylene).

The mixture may include various optional components which are additives commonly employed with polar organic liquids. Such optional components include nucleating agents, fillers, plasticizers, impact modifiers, chain extenders, plasticizers, colorants, mold release lubricants, antistatic agents, pigments, fire retardants, and the like. These optional components and appropriate amounts are well known to those skilled in the art.

The amount of intercalated and/or exfoliated layered material included in the liquid carrier or solvent compositions to form the viscous compositions suitable to deliver the carrier or some carrier-dissolved dissolved or carrier-dispersed active material, such as a pharmaceutical, may vary widely depending on the intended use and desired viscosity of the composition. For example, relatively higher amounts of intercalates, i.e., from about 10% to about 30% by weight of the total composition, are used in forming solvent gels having extremely high viscosities, e.g., 5,000 to 5,000,000 centipoises. Extremely high viscosities, however, also can be achieved with a relatively small concentration of intercalates and/or exfoliates thereof, e.g., 0.1% to 5% by weight, by adjusting the pH of the composition in the range of about 0-6 or about 10-14 and/or by heating the composition above room temperature, e.g., in the range of about 25° C. to about 200° C., preferably about 75° C. to about 100° C. It is preferred that the intercalate or platelet loading be less than about 10% by weight of the composition. Intercalate or platelet particle loadings within the range of about 0.01% to about 40% by weight, preferably about 0.05% to about 20%, more preferably about 0.5% to about 10% of the total weight of the composition significantly increases the viscosity of the composition. In general, the amount of intercalate and/or platelet particles incorporated into the carrier/solvent is less than about 20% by weight of the total composition, and preferably from about 0.05% to about 20% by weight of the composition, more preferably from about 0.01% to about 10% by weight of the composition, and most preferably from about 0.01% to about 5%, based on the total weight of the composition.

In accordance with an important feature of the present invention, the intercalate and/or platelet/carrier compositions of the present invention can be manufactured in a concentrated form, e.g., as a master gel, e.g, having about 10-90%, preferably about 20-80% intercalate and/or exfoliated platelets of layered material and about 10-90%, preferably about 20-80% carrier/solvent. The master gel can be later diluted and mixed with additional carrier or solvent to reduce the viscosity of the composition to a desired level.

The intercalates, and/or exfoliates thereof, are mixed with a carrier or solvent to produce viscous compositions of the carrier or solvent optionally including one or more active compounds, such as an antiperspirant compound, dissolved or dispersed in the carrier or solvent.

In accordance with an important feature of the present invention, a wide variety of topically-active compounds can be incorporated into a stable composition of the present invention. Such topically active compositions include cosmetic, industrial, and medicinal compounds that act upon contact with the skin or hair, or are used to adjust rheology of industrial greases and the like. In accordance with another important feature of the present invention, a topically-active compound can be solubilized in the composition of the present invention or can be homogeneously dispersed throughout the composition as an insoluble, particulate material. In either case topically-effective compositions of the present invention are resistant to composition separation and effectively apply the topically-active compound to the skin or hair. If required for stability, a surfactant can be included in the composition, such as any disclosed in Laughlin, et al. U.S. Pat. No. 3,929,678, hereby incorporated by reference. In general, the topically-effective compositions of the present invention demonstrate essentially no phase separation if the topically-active compound is solubilized in the compositions. Furthermore, if the topically-active compound is insoluble in the composition, the composition demonstrates essentially no phase separation.

The topically-active compounds can be a cosmetically-active compound, a medically-active compound or any other compound that is useful upon application to the skin or hair. Such topically-active compounds include, for example, antiperspirants, antidandruff agents, antibacterial compounds, antifungal compounds, anti-inflammatory compounds, topical anesthetics, sunscreens and other cosmetic and medical topically-effective compounds.

Therefore, in accordance with an important feature of the present invention, the stable topically-effective composition can include any of the generally-known antiperspirant compounds such as finely-divided solid astringent salts, for example, aluminum chlorohydrate, aluminum chlorohydrox, zirconium chlorohydrate, and complexes of aluminum chlorohydrate with zirconyl chloride or zirconyl hydroxychloride. In general, the amount of the antiperspirant compound, such as aluminum zirconium tetrachlorohydrex glycine in the composition can range from about 0.01% to about 50%, and preferably from about 0.1% to about 30%, by weight of the total composition.

Other topically-active compounds can be included in the compositions of the present invention in an amount sufficient to perform their intended function. For example, zinc oxide, titanium dioxide or similar compounds can be included if the composition is intended to be a sunscreen. Similarly, topically-active drugs, like antifungal compounds; antibacterial compounds; anti-inflammatory compounds; topical anesthetics; skin rash, skin disease and dermatitis medications; and anti-itch and irritation-reducing compounds can be included in the compositions of the present invention. For example, analgesics such as benzocaine, dyclonine hydrochloride, aloe vera and the like; anesthetics such as butamben picrate, lidocaine hydrochloride, zylocaine and the like; antibacterials and antiseptics, such as povidone-iodine, polymyxin b sulfate-bactracin, zinc-neomycin sulfate-hydrocortisone, chloramphenicol, methylbenzethonium chloride, and erythromycin and the like; antiparasitics, such as lindane; deodorants, such as chlorophyllin copper complex, aluminum chloride, aluminum chloride hexahydrate, and methylbenzethonium chloride; essentially all dermatologicals, like acne preparations, such as benzoyl peroxide, erythromycin-benzoyl peroxide, clindamycin phosphate, 5,7-dichloro-8-hydroxyquinoline, and the like; anti-inflammatory agents, such as alclometasone dipropionate, betamethasone valerate, and the like; burn relief ointments, such as o-amino-p-toluenesulfonamide monoacetate and the like; depigmenting agents, such as monobenzone; dermatitis relief agents, such as the active steroids amcinonide, diflorasone diacetate, hydrocortisone, and the like; diaper rash relief agents, such as methylbenzethonium chloride and the like; emollients and moisturizers, such as mineral oil, PEG-4 dilaurate, lanolin oil, petrolatum, mineral wax and the like; fungicides, such as butocouazole nitrate, haloprogin, clotrimazole, and the like; herpes treatment drugs, such as 9- (2-hydroxyethoxy)methyl!guanine; pruritic medications, such as alclometasone dipropionate, betamethasone valerate, isopropyl myristate MSD, and the like; psoriasis, seborrhea and scabicide agents, such as anthralin, methoxsalen, coal tar and the like; sunscreens, such as octyl p-(dimethylamino)benzoate, octyl methoxycinnamate, oxybenzone and the like; steroids, such as 2-(acetyloxy)-9-fluoro-1',2',3',4'-tetrahydro-11-hydroxypregna-1,4-dieno 16,17-b!naphthalene-3,20-dione, and 21-chloro-9-fluoro1',2',3',4'-tetrahydro-11b-hydroxypregna-1,4dieno 16z,17-b!naphthalene-3,20-dione. Any other medication capable of topical administration also can be incorporated in composition of the present invention in an amount sufficient to perform its intended function.

Eventual exfoliation of the intercalated layered material should provide delamination of at least about 90% by weight of the intercalated material to provide a more viscous composition comprising a carrier or solvent having monomer-complexed platelet particles substantially homogeneously dispersed therein. Some intercalates require a shear rate that is greater than about 10 sec⁻¹ for such relatively thorough exfoliation. Other intercalates exfoliate naturally or by heating, or by applying low pressure, e.g., 0.5 to 60 atmospheres above ambient, with or without heating. The upper limit for the shear rate is not critical. In the particularly preferred embodiments of the invention, when shear is employed for exfoliation, the shear rate is from greater than about 10 sec⁻¹ to about 20,000 sec⁻¹, and in the more preferred embodiments of the invention the shear rate is from about 100 sec⁻¹ to about 10,000 sec⁻¹.

When shear is employed for exfoliation, any method which can be used to apply a shear to the intercalant/carrier composition can be used. The shearing action can be provided by any appropriate method, as for example by mechanical means, by thermal shock, by pressure alteration, or by ultrasonics, all known in the art. In particularly useful procedures, the composition is sheared by mechanical methods in which the intercalate, with or without the carrier or solvent, is sheared by use of mechanical means, such as stirrers, Banbury® type mixers, Brabender® type mixers, long continuous mixers, and extruders. Another procedure employs thermal shock in which shearing is achieved by alternatively raising or lowering the temperature of the composition causing thermal expansions and resulting in internal stresses which cause the shear. In still other procedures, shear is achieved by sudden pressure changes in pressure alteration methods; by ultrasonic techniques in which cavitation or resonant vibrations which cause portions of the composition to vibrate or to be excited at different phases and thus subjected to shear. These methods of shearing are merely representative of useful methods, and any method known in the art for shearing intercalates may be used.

Mechanical shearing methods may be employed such as by extrusion, injection molding machines, Banbury® type mixers, Brabender® type mixers and the like. Shearing also can be achieved by introducing the layered material and intercalant monomer at one end of an extruder (single or double screw) and receiving the sheared material at the other end of the extruder. The temperature of the layered material/intercalant monomer composition, the length of the extruder, residence time of the composition in the extruder and the design of the extruder (single screw, twin screw, number of flights per unit length, channel depth, flight clearance, mixing zone, etc.) are several variables which control the amount of shear to be applied for exfoliation.

Exfoliation should be sufficiently thorough to provide at least about 80% by weight, preferably at least about 85% by weight, more preferably at least about 90% by weight, and most preferably at least about 95% by weight delamination of the layers to form individual platelet particles that can be substantially homogeneously dispersed in the carrier or solvent. As formed by this process, the platelet particles dispersed in the carrier or solvent have the thickness of the individual layers plus one to five monolayer thicknesses of complexed monomer, or small multiples less than about 10, preferably less than about 5 and more preferably less than about 3 of the layers, and still more preferably 1 or 2 layers. In the preferred embodiments of this invention, intercalation and delamination of every interlayer space is complete so that all or substantially all individual layers delaminate one from the other to form separate platelet particles for admixture with the carrier or solvent. The compositions can include the layered material as all intercalate, completely without exfoliation, initially to provide relatively low viscosities for transportation and pumping until it is desired to increase viscosity via easy exfoliation. In cases where intercalation is incomplete between some layers, those layers will not delaminate in the carrier or solvent, and will form platelet particles comprising those layers in a coplanar aggregate.

The effect of adding into a polar organic liquid carrier the nanoscale particulate dispersed platelet particles, derived from the intercalates formed in accordance with the present invention, typically is an increase in viscosity.

Molding compositions comprising a thermoplastic or thermosetting polymer containing a desired loading of platelets obtained from exfoliation of the intercalates manufactured according to the invention are outstandingly suitable for the production of sheets and panels having valuable properties. Such sheets and panels may be shaped by conventional processes such as vacuum processing or by hot pressing to form useful objects. The sheets and panels according to the invention are also suitable as coating materials for other materials comprising, for example, wood, glass, ceramic, metal or other plastics, and outstanding strengths can be achieved using conventional adhesion promoters, for example, those based on vinyl resins. The sheets and panels can also be laminated with other plastic films and this is preferably effected by co-extrusion, the sheets being bonded in the molten state. The surfaces of the sheets and panels, including those in the embossed form, can be improved or finished by conventional methods, for example by lacquering or by the application of protective films.

Matrix polymer/platelet composite materials are especially useful for fabrication of extruded films and film laminates, as for example, films for use in food packaging. Such films can be fabricated using conventional film extrusion techniques. The films are preferably from about 10 to about 100 microns, more preferably from about 20 to about 100 microns and most preferably from about 25 to about 75 microns in thickness.

The homogeneously distributed platelet particles, exfoliated in accordance with the present invention, and matrix polymer that form the nanocomposites of one embodiment of the present invention are formed into a film by suitable film-forming methods. Typically, the composition is melted and forced through a film forming die. The film of the nanocomposite may go through steps to cause the platelets to be further oriented so the major planes through the platelets are substantially parallel to the major plane through the film. A method to do this is to biaxially stretch the film. For example, the film is stretched in the axial or machine direction by tension rollers pulling the film as it is extruded from the die. The film is simultaneously stretched in the transverse direction by clamping the edges of the film and drawing them apart. Alternatively, the film is stretched in the transverse direction by using a tubular film die and blowing the film up as it passes from the tubular film die. The films may exhibit one or more of the following benefits: increased modulus; increased wet strength; increased dimensional stability; decreased moisture adsorption; decreased permeability to gases such as oxygen and liquids, such as water, alcohols and other solvents.

EXAMPLE 1 Preparation of Clay--Monomeric Carbonyl-Functional Complexes (Intercalates)

Materials: Clay--sodium montmorillonite;

Monomeric Carbonyl-Functional Compound--butyraldehyde

To prepare Clay (sodium montmorillonite)--butyraldehyde complexes (intercalates) three different processes are used for monomer intercalation:

1. Mixture of the 2% butyraldehyde/water solution with the 2% clay/water suspension in a ratio sufficient to provide a butyraldehyde concentration of at least about 8% based on the dry weight of the clay.

2. Dry clay powder (about 8% by weight moisture) is gradually added to the 2% butyraldehyde/water solution in a ratio sufficient to provide a butyraldehyde concentration of at least about 8% based on the dry weight of the clay.

3. Dry butyraldehyde is mixed with dry clay, the mixture is hydrated with 35-38% of water, based on the dry weight of the clay, and then extruded.

Mixtures 1 and 2 are agitated at room temperature during 4 hours.

The intercalation and exfoliation methods of the present invention yield the Clay--butyraldehyde complexes (intercalates), and the results of the intercalation do not depend on the method of preparation (1, 2, or 3), but do depend on the quantity of monomeric carbonyl functional sorbed between clay platelets.

EXAMPLE 2 Preparation of Clay--Monomeric Carboxylic Acid-Functional Compound Complexes (Intercalates)

Materials: Clay--sodium montmorillonite;

Monomeric Carboxylic Acid-Functional Compound: acrylic acid/sodium acrylate mixture

To prepare Clay (sodium montmorillonite)--acrylic acid/sodium acrylate complexes (intercalates) three different processes are used for carboxylic acid monomer intercalation:

1. Mixture of the 2% carboxylic acid-functional compounds/water solution with the 2% sodium montmorillonite clay/water suspension in a ratio sufficient to provide a carboxylic acid-functional compound concentration of at least about 8% based on the dry weight of the clay.

2. Dry clay powder is gradually added to the 2% carboxylic acid-functional compounds/water solution in a ratio sufficient to provide a carboxylic acid-functional compound concentration of at least about 8% based on the dry weight of the sodium montmorillonite clay.

3. Dry sodium montmorillonite clay is moisturized with carboxylic acid-functional compound/water solution to 20-80% by weight water, and then extruded.

The mixtures 1 and 2 are agitated at room temperature during 4 hours.

A mixture of 30% by weight acrylic acid (AAc) and 70% by weight sodium acrylate (NaAAc) was prepared in water, at a concentration of 45% by weight AAc and NaAAc and a pH of 6. In a 50 ml beaker, 30 grams of the AAc/NaAAc mixture was added, and while this mixture was being mixed vigorously, 1.5 grams of sodium montmorillonite¹ was added. The weight ratio of clay to (AAc +NaAAc)=1.9. The mixture was vigorously mixed and heated for 1 hour at 85° C.

The heated mixture was allowed to cool to room temperature and subjected to x-ray diffraction. The x-ray diffraction pattern is shown in FIG. 4. As shown in FIG. 4, the AAc/NaAAc:clay complexed since no d(001) smectite peak appears at about 12.4 Å, and peaks appear at about 22 Å, and 32 Å representative of acrylic acid intercalated between clay platelets. The peak at 11.29 Å is representative of acrylic acid.

All methods of the present invention used for intercalation yield the composite Clay--carboxylic acid-functional compound complexes (intercalates), and the results of the intercalation do not depend on the method of preparation (1, 2, or 3), but do depend on the quantity of monomeric carboxylic acid-functional compound sorbed between clay platelets.

Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the process may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved. 

What is claimed is:
 1. An intercalate, capable of being exfoliated, formed by contacting a layered material, having adjacent platelets of said layered material, having a moisture content of at least about 4% by weight, with water and an intercalant monomer to form an intercalating composition comprising said layered material, water and said intercalant monomer, said intercalant monomer having a functionality selected from the group consisting of a carbonyl; a carboxylic acid or salt thereof; and mixtures thereof, said intercalate having a weight ratio of intercalant monomer to layered material of at least about 1:20, to achieve sorption and complexing of the intercalant monomer between adjacent spaced layers of the layered material, without an onium ion or silane coupling agent, to expand the spacing between a predominance of the adjacent platelets of said layered material to at least about 5 Å, when measured after sorption of the intercalant monomer and drying to a maximum of 5% by weight water.
 2. An intercalate in accordance with claim 1, wherein the concentration of intercalant monomer in said intercalant monomer-containing composition is at least about 0.1% by weight, based on the weight of water and intercalant monomer in the intercalating composition.
 3. An intercalate in accordance with claim 2, wherein the concentration of intercalant monomer in said intercalating composition is at least about 2% by weight.
 4. An intercalate in accordance with claim 3, wherein the concentration of intercalant monomer in said intercalating composition is at least about 5% by weight.
 5. An intercalate in accordance with claim 4, wherein the concentration of intercalant monomer in said intercalating composition is at least about 30% by weight.
 6. An intercalate in accordance with claim 4, wherein the concentration of intercalant monomer in said intercalating composition in the range of about 10% to about 60% by weight.
 7. An intercalate in accordance with claim 5, wherein the concentration of intercalant monomer in said intercalating composition in the range of about 50% to about 90% by weight.
 8. An intercalate in accordance with claim 1, wherein the concentration of intercalant monomer in the intercalating composition is at least about 15% by weight, based on the dry weight of the layered material.
 9. An intercalate in accordance with claim 8, wherein the concentration of intercalant monomer in the intercalating composition is in the range of about 16% to about 70% by weight, based on the dry weight of the layered material.
 10. An intercalate in accordance with claim 9, wherein the concentration of intercalant monomer in the intercalating composition is in the range of about 16% to less than about 35% by weight, based on the dry weight of the layered material.
 11. An intercalate in accordance with claim 9, wherein the concentration of intercalant monomer in the intercalating composition is in the range of about 35% to less than about 55% by weight, based on the dry weight of the layered material.
 12. An intercalate in accordance with claim 8, wherein the concentration of the intercalant monomer in the intercalating composition is at least about 16% by weight, based on the dry weight of the layered material in the intercalating composition, to achieve spacing between adjacent platelets of said layered material of at least about 10 Å.
 13. An intercalate in accordance with claim 8, wherein the intercalant monomer is an organic carbonyl-functional compound and is present in said intercalating composition in a concentration of at least about 2%, based on the weight of water and organic hydrocarbons in said intercalating composition.
 14. An intercalate in accordance with claim 1, wherein the intercalant monomer is an organic carboxylic acid-functional compound.
 15. A composition in accordance with claim 1, wherein the weight ratio of intercalant monomer to layered material in the intercalating composition is in the range of about 1:20 to about 10:1.
 16. A composition in accordance with claim 1, wherein the weight ratio of intercalant monomer to layered material is at least 1:12.
 17. A composition in accordance with claim 16, wherein the weight ratio of intercalant monomer to layered material in the intercalating composition is at least 1:5.
 18. A composition in accordance with claim 17, wherein the weight ratio of intercalant monomer to layered material in the intercalating composition is in the range of 1:5 to 1:3.
 19. A composition in accordance with claim 15, wherein the weight ratio of intercalant monomer to layered material in the intercalating composition is in the range of 1:20 to about 9:1.
 20. A method of intercalating a phyllosilicate comprising:contacting the phyllosilicate, having adjacent phyllosilicate platelets and having a moisture content of at least about 4% by weight, with an intercalating composition comprising said phyllosilicate, water, and, an intercalant monomer, said intercalating composition having a weight ratio intercalant monomer to phyllosilicate in said intercalating composition of at least about 1:20 and said intercalant monomer having a functionality selected from the group consisting of a carbonyl; a carboxylic acid; a carboxylic acid salt; and mixtures thereof, to achieve intercalation of said intercalant monomer between said adjacent phyllosilicate platelets, without an onium ion or silane coupling agent, in an amount sufficient to space said adjacent phyllosilicate platelets a distance of at least about 5 Å.
 21. The method of claim 20, further including the step of separating the platelets of the intercalated phyllosilicate into predominantly individual platelets.
 22. The method of claim 20, wherein said intercalating composition includes a water carrier comprising about 5% to about 50% by weight water, based on the total weight of liquids in said intercalating composition.
 23. The method of claim 22, wherein said liquids in said intercalating composition comprise about 10% to about 40% by weight water.
 24. A composition comprising an organic liquid carrier in an amount of about 40% to about 99.95% by weight of the composition, and about 0.05% to about 60% by weight of an intercalated phyllosilicate material, said intercalated phyllosilicate material formed by contacting a phyllosilicate, having adjacent phyllosilicate platelets, and having a water content of at least about 7% by weight, with water and an intercalant monomer to form an intercalating composition, said intercalant monomer included in said intercalating composition in a weight ratio of intercalant monomer:phyllosilicate of at least about 1;20, said intercalant monomer having a functionality selected from the group consisting of a carbonyl; a carboxylic acid; a carboxylic acid salt; and mixtures thereof to achieve sorption of the intercalant monomer between adjacent spaced layers of phyllosilicate without an onium ion or silane coupling agent, sufficient to expand the spacing between a predominance of the adjacent phyllosilicate platelets to at least about 5 Å, when measured after sorption of the intercalant monomer and at a maximum water content of about 5% by weight, based on the dry weight of the phyllosilicate.
 25. The composition of claim 24, wherein the intercalate is exfoliated into a predominance of single platelets.
 26. A composition in accordance with claim 24, wherein said intercalating composition comprises the phyllosilicate, an intercalant monomer and water, and wherein the concentration of intercalant monomer in said intercalating composition is at least about 5% by weight, based on the dry weight of the phyllosilicate in the intercalating composition.
 27. A composition in accordance with claim 26, wherein the concentration of intercalant monomer in said intercalating composition is at least about 15% by weight, based on the dry weight of the phyllosilicate in the intercalating composition.
 28. A composition in accordance with claim 27, wherein the concentration of intercalant monomer in said intercalating composition is at least about 20% by weight.
 29. A composition in accordance with claim 28, wherein the concentration of intercalant monomer in said phyllosilicate-contacting composition is at least about 30% by weight.
 30. A composition in accordance with claim 29, wherein the concentration of intercalant monomer in said intercalating composition in the range of about 50% to about 90% by weight.
 31. A composition in accordance with claim 30, wherein the concentration of intercalant monomer in said intercalating composition in the range of about 50% to about 80% by weight, and wherein the intercalating composition does not include a compound having an onium ion or a silane coupling agent.
 32. A composition in accordance with claim 24, wherein the concentration of intercalant monomer in the intercalating composition is at least about 16% by weight, based on the dry weight of the phyllosilicate.
 33. A composition in accordance with claim 32, wherein the concentration of intercalant monomer in the intercalating composition is in the range of about 16% to about 70% by weight, based on the dry weight of the phyllosilicate.
 34. A composition in accordance with claim 33, wherein the concentration of intercalant monomer in the intercalating composition is in the range of about 16% to less than about 35% by weight, based on the dry weight of the phyllosilicate.
 35. A composition in accordance with claim 33, wherein the concentration of intercalant monomer in the intercalating composition is in the range of about 35% to less than about 55% by weight, based on the dry weight of the phyllosilicate.
 36. A composition in accordance with claim 33, wherein the concentration of the intercalant monomer in the intercalating composition is in the range of about 55% to less than about 70% by weight, based on the dry weight of the phyllosilicate.
 37. A composite material comprising the intercalate of claim 1, in a concentration of about 0.05% to about 60% by weight, and a matrix polymer selected from the group consisting of a polyamide; polyvinyl alcohol; polycarbonate; polyvinylimine; polyethylene terephthalate; polybutylene terephthalate; a polymer polymerized from a monomer selected from the group consisting of dihydroxyethyl terephthalate; dihydroxybutyl terephthalate; hydroxyethylmethyl terephthalate; hydroxybutylmethyl terephthalate; and mixtures thereof.
 38. A composite material in accordance with claim 37, wherein the matrix polymer is a mixture of a polymer of hydroxyethyl terephthalate with a polymer polymerized from a monomer selected from the group consisting of dihydroxyethyl terephthalate and dihydroxybutyl terephthalate, and mixtures thereof.
 39. A composite material in accordance with claim 37, wherein the matrix polymer is polyethylene terephthalate.
 40. A method of manufacturing a composite material containing about 10% to about 99.95% by weight of a matrix polymer selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and mixtures thereof, and about 0.05% to about 60% by weight of exfoliated platelets of a phyllosilicate material, said platelets derived from an intercalated phyllosilicate having an intercalant monomer intercalated between and bonded to an inner surface of the phyllosilicate platelets through a bonding mechanism selected from the group consisting of ionic complexing; electrostatic complexing; chelation; hydrogen bonding; dipole/dipole; Van Der Walls forces; and any combination thereof comprising:contacting the phyllosilicate, having adjacent phyllosilicate platelets and having a moisture content of at least about 4% by weight, with water and an intercalant monomer, said intercalant monomer having a functionality selected from the group consisting of a carbonyl; a carboxylic acid; a carboxylic acid salt; and mixtures thereof, to achieve intercalation of said intercalant monomer between said adjacent phyllosilicate platelets, without an onium ion or silane coupling agent, in an amount sufficient to space said adjacent phyllosilicate platelets a distance of at least about 5 Å; combining the intercalate with said matrix polymer; exfoliating the spaced platelets of said intercalate into predominantly individual platelets; and dispersing said exfoliated platelets throughout said matrix polymer.
 41. The method of claim 40, wherein said phyllosilicate is contacted with said water in an intercalating composition including said water, said intercalant monomer, said phyllosilicate, and a liquid polar organic hydrocarbon carrier and wherein said intercalating composition comprises about 5% to about 50% by weight water, based on the dry weight of said phyllosilicate.
 42. The method of claim 40, wherein said intercalating composition comprises about 10% to about 90% by weight of said polar organic liquid hydrocarbon, based on the dry weight of the phyllosilicate.
 43. A method of manufacturing a composition comprising an organic liquid and a phyllosilicate intercalate comprising:contacting the phyllosilicate with an intercalating composition comprising the phyllosilicate, an intercalant monomer, and water, wherein the weight ratio of the intercalant monomer to phyllosilicate is at least about 1 to 20, and the concentration of said intercalant monomer is at least about 5% up to about 900% intercalant monomer, based on the dry weight of the phyllosilicate, to form an intercalate having said intercalant monomer intercalated between said adjacent phyllosilicate platelets, without an onium ion or silane coupling agent, in an amount sufficient to space said adjacent phyllosilicate platelets to a distance of at least about 5 Å; and combining the intercalate with said organic liquid. 